U.S. patent number 3,752,616 [Application Number 05/143,217] was granted by the patent office on 1973-08-14 for mix-spinning apparatus.
This patent grant is currently assigned to Kanegafuchi Boseki Kabushiki Kaisha. Invention is credited to Masao Matsui, Masahiro Yamabe.
United States Patent |
3,752,616 |
Matsui , et al. |
August 14, 1973 |
MIX-SPINNING APPARATUS
Abstract
A spinning apparatus capable of manufacturing a multi-layer
filament from at least two-spinning materials by using a
layer-multiplying mixer consisting of a three-dimensional passage
network which include at least two network elements arranged in
successive stages, the network element being composed of repeated
unit passages arranged on a plane, whereby the spinning materials
are joined and separated in different phase in multi-stages.
Inventors: |
Matsui; Masao (Takatsuki,
JA), Yamabe; Masahiro (Neyagawa, JA) |
Assignee: |
Kanegafuchi Boseki Kabushiki
Kaisha (Tokyo, JA)
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Family
ID: |
26348038 |
Appl.
No.: |
05/143,217 |
Filed: |
May 13, 1971 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
Issue Date |
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783508 |
Dec 13, 1968 |
3613173 |
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Foreign Application Priority Data
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Dec 20, 1967 [JA] |
|
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42/82022 |
Feb 27, 1968 [JA] |
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43/12426 |
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Current U.S.
Class: |
425/131.5;
425/382.2; 425/463 |
Current CPC
Class: |
D01D
1/065 (20130101); B01F 5/0603 (20130101); Y10S
425/217 (20130101) |
Current International
Class: |
D01D
1/06 (20060101); D01D 1/00 (20060101); B01F
5/06 (20060101); D01d 003/00 () |
Field of
Search: |
;425/382,131,132,133,198,464,463 ;264/176F,177 |
References Cited
[Referenced By]
U.S. Patent Documents
Primary Examiner: Overholzer; J. Spencer
Assistant Examiner: Sutton; Michael O.
Parent Case Text
This application is a division of our co-pending application Ser.
No. 783,508, filed Dec. 13, 1968, and now U.S. Pat. No. 3,613,173.
Claims
What is claimed is:
1. A mix-spinning apparatus for spinning at least two different
kinds of spinning materials comprising
I. a member for supplying at least two different kinds of spinning
materials, a spinneret plate having at least one orifice, and a
mixer for stratifying said spinning materials into multi-layers and
interposed between the member and the spinneret plate,
Ii. said mixer consisting of a three-dimensional passage network
which includes at least two network elements disposed one upon the
other in successive stages, an outlet portion of the network
element at each stage being connected to an inlet portion of the
network element of the next stage,
Iii. the main part of said network element, including at least one,
preferably at least two unit passages arranged on a substantial
plane in a regular manner,
Iv. said unit passage including
a. a main passage L having at least one branch M on a substantial
plane and at least one inlet I through which the spinning materials
flow in a direction substantially perpendicular to said plane and
at least one outlet O through which the spinning materials flow out
in a direction substantially perpendicular to said plane,
b. said main passage being a closed zigzag form,
c. said inlet I and outlet O being arranged alternately along said
main passage,
d. said inlet I being provided on said branch M or main passage
L,
e. said outlet O being provided on said branch M or main passage
L,
V. at least two different kinds of spinning materials supplied into
said mixer being joined and separated at least two stages in
different phase and flowed out from said orifice on the spinneret
plate.
2. The spinning apparatus of claim 1 wherein said network element
includes at least two types of unit passages connected to each
other.
3. The spinning apparatus of claim 1 wherein said mixer is a
combination of at least two kinds of network elements.
4. The spinning apparatus of claim 1 wherein said mixer consists of
at least two kinds of said distributing plates superposed one upon
the other.
5. A mix-spinning apparatus for spinning at least two different
kinds of spinning materials comprising
I. a member for supplying at least two different kinds of spinning
materials, a spinneret plate having at least one orifice, and a
mixer for stratifying said spinning materials into multi-layers and
interposed between the member and the spinneret plate,
Ii. said mixer consisting of a three-dimensional passage network
which includes at least two network elements disposed one upon the
other in successive stages, an outlet portion of the network
element at each stage being connected to an inlet portion of the
network element of the next stage,
Iii. the main part of said network element, including at least one,
preferably at least two unit passages arranged on a substantial
plane in a regular manner,
Iv. said unit passage including
a. a main passage L having at least one branch M on a substantial
plane and at least one inlet I through which the spinning materials
flow in a direction substantially perpendicular to said plane,
b. said main passage being a closed ladder form,
c. said inlet I and outlet O being arranged alternately along said
main passage,
d. said inlet I being provided on said branch M or main passage
L,
e. said outlet O being provided on said branch M or main passage
L,
V. at least two different kinds of spinning materials supplied into
said mixer being joined and separated at least two stages in
different phase and flowed out from said orifice on the spinneret
plate.
6. A mix-spinning apparatus for spinning at least two different
kinds of spinning materials comprising
I. a member for supplying at least two different kinds of spinning
materials, a spinneret plate having at least one orifice, and a
mixer for stratifying said spinning materials into multi-layers and
interposed between the member and the spinneret plate,
Ii. said mixer consisting of a three-dimensional passage network
which includes at least two network elements disposed one upon the
other in successive stages, an outlet portion of the network
element at each stage being connected to an inlet portion of the
network element of the next stage,
Iii. the main part of said network element, including at least one,
preferably at least two unit passages arranged on a substantial
plane in a regular manner,
Iv. said unit passage including
a. a main passage L having at least one branch M on a substantial
plane and at least one inlet I through which the spinning materials
flow in a direction substantially perpendicular to said plane and
at least one outlet O through which the spinning materials flow out
in a direction substantially perpendicular to said plane,
b. said main passage being a closed lattice form,
c. said inlet I and outlet O being arranged alternately along said
main passage,
d. said inlet I being provided on said branch M or main passage
L,
e. said outlet O being provided on said branch M or main passage
L,
V. at least two different kinds of spinning material supplied into
said mixer being joined and separated at least two stages in
different phase and flowed out from said orifice on the spinneret
plate.
Description
This invention relates to a mix-spinning apparatus capable of
easily manufacturing a mixed filament, particularly a multi-layer
filament comprising a plurality of components laminated one upon
the other to form a unitary filament.
A multi-layer filament comprising at least two different kinds of
components laminated one upon the other substantially continuously
along an axial direction of a unitary filament has many important
advantages and improved properties when compared with a
conventional filament having a granular or needle like mixed
construction. For example, the conventional mixed filament has such
construction that it is not continuous in its longitudinal
direction and hence the filament when subjected to tensile stress,
bending stress or elongation is apt to restore to its original
state in a lesser extent. The multi-layer filament has not such
disadvantage inherent to the non-continuous construction. However,
it is considerably difficult to spin the multi-layer filament in an
efficient manner. Apparatuses for spinning the multi-layer filament
which are extremely complex in construction and difficult in
maintenance are described in Belgian patent specification No.
694,233 and French patent specification No. 1,495,835. A
comparatively simple apparatus is described in U.S. Pat. No.
3,382,534. This apparatus makes it quite difficult to spin
simultaneously uniform multi-layer filament through, for example, a
number of orifices.
The principal object of the invention is to provide a spinneret
adapted to manufacture the above mentioned multi-layer filament,
particularly uniform mixed filament in a highly efficient
manner.
Another object of the invention is to provide a mix-spinning
apparatus which is comparatively simple in construction and can
easily be manufactured, assembled and maintained.
The inventors proposed in Dutch patent application No. 6,803,699 a
spinning apparatus which is comparatively simple in construction
and adapted to efficiently manufacture a uniform multi-layer
filament. The spinning apparatus proposed by the inventors
comprises a member for supplying spinning material, a spinneret
plate, and a mixer consisting of a plurality of reservoirs located
between the member for supplying the spinning material and the
spinneret plate, and distributing passages for communicating the
reservoirs each other. Such mixer or spinneret has the advantage
that it can be manufactured in an extremely simple manner, but has
the disadvantages that it cannot be made small without difficulty
and that the flow of the spinning material becomes irregular. That
is, the presence of the reservoirs affords the limitation that the
apparatus cannot be made small, while the flow of the spinning
material is easily disturbed owing to occurrence of stagnation of
the spinning material therein. It is a matter of course that the
above mentioned spinneret is useful owing to its simple
construction irrespective of the above mentioned disadvantages.
The invention makes use of a layer-multiplying mixer having no
reservoirs, that is a mixer consisting of passages only. The
passage means a narrow path admitting the flow of the spinning
material.
The spinning apparatus according to the invention is characterized
in comprising
I. a member for supplying at least two different kinds of spinning
materials, a spinneret plate having at least one orifice, and a
mixer for stratifying said spinning materials into multi-layers and
interposed between the member and the spinneret,
Ii. said mixer consisting of a three-dimensional passage network
which includes at least two "network elements" arranged in
successive stages, an outlet portion of the network element at each
stage being connected to an inlet portion of the network element at
the next stage,
Iii. the main part of said network element including at least one,
preferably at least two "unit passages" arranged on a substantial
plane in a regular manner,
Iv. said unit passage including
a. a main passage having at least one branch on a substantial plane
and at least one inlet through which the spinning materials flow in
a direction substantially perpendicular to said plane and at least
one outlet through which the spinning materials flow out in a
direcection substantially perpendicular to said plane,
b. said inlet and outlet being arranged alternately along said main
passage,
c. said inlet and outlet being provided on said branch and/or main
passage,
V. at least two different kinds of spinning materials supplied into
said mixer being joined and separated at least two stages in
different phase and flowed out from the orifices.
As seen from the above, the method of spinning multi-layer filament
according to the invention is based on such idea that different
kinds of spinning materials are joined and separated at many stages
thus forming the spinning materials into a multi-layer
filament.
For a better understanding of the invention, reference is taken to
the accompanying drawings, of which
FIG. 1 is a sectional view of a conventional side-by-side type
composite filament obtained by joining two spinning materials at
one time;
FIG. 2 is a sectional view of a four-layer filament according to
the invention;
FIG. 3 is a sectional view of a filament having a grainy
multi-layer construction according to the invention;
FIG. 4 is a sectional view of a filament having a distorted grainy
multi-layer construction according to the invention;
FIG. 5 is a sectional view of a filament having an archipelagic
configuration according to the invention;
FIG. 6 is a sectional view of a filament having a nebular
configuration according to the invention;
FIG. 7 is a view illustrating a basic method of stratifying two
spinning materials into multi-layers;
FIG. 8 is a similar view to FIG. 7 illustrating a modified method
of multiplication of layer;
FIG. 9 is a view illustrating a method of stratifying three
spinning materials into multi-layers according to the
invention;
FIGS. 10 - 13 are diagrams showing various embodiments of a network
element having one inlet and one outlet;
FIGS. 14 - 18 are diagrams illustrating various methods of
supplying spinning materials into an inlet;
FIGS. 19 - 30 are perspective views illustrating separating and
joining states of spinning materials at the passage;
FIGS. 31 - 34 are diagrams showing several embodiments of a unit
passage having two inlets and outlets, and two branches,
respectively;
FIGS. 35 - 57 are diagrams showing various embodiments of the
network element composed of the various unit passages (repeating
units);
FIGS. 58, 59 and 60 show embodiments of three-dimensional passage
network constructed by connecting the network elements in
multi-stages;
FIG. 61 is a vertical-sectional view of spinneret according to the
invention;
FIG. 62 is a base surface of a distributing plate shown in FIG.
61;
FIG. 63 is a vertical sectional view of another distributing
plate;
FIG. 64 is a plan views showing upper surface of the distributing
plate shown in FIG. 63;
FIG. 65 is a bottom view of the distributing plate shown in FIG.
63;
FIG. 66 is a vertical sectional view of a distributing plate
composed of three plates;
FIGS. 67, 68 and 69 are cross-sectional views of the distributing
plate shown in FIG. 66 taken on lines 1-1', 2-2' and 3-3'
respectively in the arrow direction;
FIG. 70 is a vertical sectional view of a spinneret having a zigzag
type element according to the present invention;
FIGS. 71, 72 and 73 are cross-sectional views of the spinneret
shown in FIG. 70 taken on lines 4-4', 5-5' and 6-6' respectivley in
the arrow direction;
FIG. 74 is a vertical sectional view of a spinneret having a ladder
type element according to the present invention; and
FIGS. 75, 76 and 77 are cross-sectional views of the spinneret
shown in FIG. 74 taken on lines 7-7', 8-8' and 9-9' respectively in
the arrow direction.
Referring now to FIG. 7, two spinning materials A and B are joined
at a point J.sub.1 to form a component AB and then the component AB
thus formed is separated at a point S.sub.1 into two components AB
and AB. The two components AB and AB thus formed are joined again
at a point J.sub.2 into a four layer structure ABAB. The spinning
materials are joined and separated such that the component AB is
separated at the point S.sub.1 into two components AB and AB with
the joined state remained at least partly, preferably completely as
they were and that the two components AB and AB are joined at the
point J.sub.2 into the four layer structure ABAB so as to add at
least partly, preferably completely the joined states. That is, the
joining direction of spinning materials is different from the
separating direction of spinning materials, and, it is most
practical and efficient that the difference of the directions is
90.degree.. The above mentioned joining and separating are called
"joining and separating in different phase". If the joining and
separating are effected in the same phase, i.e. in the same
direction, the two spinning materials A and B could not be
layer-multiplied.
FIG. 1 shows in section a conventional side-by-side type composite
filament obtained by joining two spinning materials A and B at one
stage.
FIG. 2 shows in section a filament obtained by joining and
separating the two spinning materials at two stages in the manner
explained with reference to FIG. 7.
FIG. 3 shows in section a filament obtained by joining and
separating the two spinning materials at a number of stages
successively.
Calculation shows that the number of the layers constituting the
filament obtained by joining and separating the two spinning
materials successively at n stages as shown in FIG. 7 is 2.sup.n. n
is called a number of joining and separating stages. The filament
obtained by joining and separating in different phase at a number
of stages shows a more or less distortion as shown in section in
FIG. 4. In practice the number of layers of the filament is given
by a value which is more or less larger or smaller than the above
mentioned calculated value 2.sup.n owing to irregular disturbance
of the flow of the spinning materials in spinneret.
FIG. 7 shows a basic type flow of the spinning materials in the
method to multiply the layer. In practice many modifications
thereof may occur to those skilled in the art. FIGS. 8 and 9 show
examples of such modifications.
If the joining at the point J.sub.2 is not perfect as shown in FIG.
8, the number of layers is not so much increased efficiently.
Calculation also shows that the number of layers constituting the
filament obtained by joining and separating three spinning
materials successively n stages as shown in FIG. 9 is 3 .times.
2.sup.n.sup.-1.
As above mentioned, if the two spinning materials are joined and
separated at a number of stages successively in different phase, a
filament having a grainy multi-layer construction as shown in FIG.
3 is obtained. However, the irregular disturbance of the flow of
the spinning material in the spinnerets often results in a filament
having a distorted grainy construction as shown in FIG. 4. If use
is made, for example, of polyester and polyamide having no affinity
each other as the spinning materials, a multi-layer filament
obtained has often an archipelagic construction as shown in FIG. 5
or a nebularly distributed construction as shown in FIG. 6.
Each of main layers in the multi-layer filament shown in FIGS. 5
and 6 is substantially continuous in the longitudinal direction of
the filament.
The network element (hereinafter is abridged as "element") or unit
passage according to the invention will now be explained with
reference to the drawing.
FIG. 10 shows an embodiment of the smallest element. This element
consists of a unit passage. The element or unit passage shown in
FIG. 10 consists of a circular main passage L, one branch M, one
inlet I and one outlet O. The spinning materials supplied to the
inlet I connected to the branch M are separated at a point S and
joined at a point J and then flow out of the outlet O. In the
element (or unit passage) shown in FIG. 10 the main passage L is
provided with the outlet O which is the same as the point J where
the spinning materials are joined together. A small circle shown by
black and white at the inlet I designates a phase or direction in
which the spinning materials joined together.
FIG. 11 shows another element in which the main passage L is
provided with the inlet I and the branch M is provided with the
outlet O, while the inlet I is the same as the separating point
S.sub.1 and the branch M and the main passage L cross at the
joining point J. Thus, the main passage L may be provided with the
inlet I and the branch M may be provided with the outlet O.
However, it is not desirable that the main passage L is provided
with both of the inlet I and the outlet O as shown in FIG. 12 and
that the branch M are provided with both of the inlet I and the
outlet O, as shown in FIG. 13, since in these cases the number of
layers is not so much increased efficiently.
The main passage L may be provided at any point thereof and in any
direction with the branch M. The branch M may be connected to the
main passage L at a direction not perpendicular thereto. The main
passage L and the branch M may be curved. But, it is necessary to
arrange the branch M and the main passage L in a substantial plane.
As will be described hereinafter, the unit passage and the element
should preferably be regular in construction.
It is most preferable to supply the spinning materials through the
inlet I to the branch M in a phase shown in FIG. 14 or to the main
passage L in a phase shown in FIG. 15. But, it is worst to supply
the spinning materials through the inlet I to the branch M in a
phase shown in FIG. 16 or to the main passage L in a phase shown in
FIG. 17. The methods of supplying the spinning materials in phases
shown in FIGS. 16 and 17 considerably reduce the layer-multiplying
efficiency. An intermediate layer-multiplying efficiency is given
by the method of supplying the spinning materials shown in FIG.
18.
FIGS. 19 - 30 show at the upper parts thereof changes of the layers
of the spinning materials when they are joined and separated at the
passages in perspective view and at the lower parts thereof in
parenthesis corresponding passages in diagram.
FIG. 19 and 20 show embodiments in which the branch M is provided
at its end with the inlet I. In the embodiment shown in FIG. 19 the
spinning materials are supplied into the inlet I in the most
preferable phase; while in the embodiment shown in FIG. 20 the
spinning materials are supplied into the inlet I in the worst
phase.
FIGS. 21 and 22 show embodiments in which the main passage L is
provided with the inlet I. In the embodiment shown in FIG. 21 the
spinning materials are supplied into the inlet I in the most
preferable phase, while in the embodiment shown in FIG. 22 the
spinning materials are supplied into the inlet I in the worst
phase.
FIGS. 23 - 26 show embodiments in which the main passage L is
provided with the outlet O. In the embodiments shown in FIGS. 23
and 25 the spinning materials are joined and then supplied into the
outlet O in the most preferable phase so as to increase the number
of layers in the most efficient manner, while in the embodiments
shown in FIG. 26 the spinning materials are joined and then
supplied into the outlet O in the worst manner without increasing
the number of layers. For example, in the embodiment shown in FIG.
24 the spinning materials are joined with the aid of the element
shown in FIG. 10 in a manner shown in FIG. 8.
FIGS. 27 - 30 show embodiments in which the branch M is provided at
its end with the outlet O. In the embodiments shown in FIGS. 27 and
29 the spinning materials are joined and then supplied into the
outlet O in the most efficient manner, while in the embodiment
shown in FIG. 28 the spinning materials are joined and then
supplied into the outlet O in less efficient manner and in the
embodiment shown in FIG. 30 the spinning materials are joined and
then supplied into the outlet O in the worst manner without
increasing the number of layers.
In the embodiments shown in FIGS. 23, 25, 27 and 29 the spinning
materials are joined in completely different phase, but in practice
the embodiments shown in FIGS. 23 and 27 are most useful.
Similarly, the embodiments shown in FIGS. 19 and 21 are most useful
for separating the spinning materials in different phase. The
reason why these embodiments are most useful will be described
hereinafter with reference to series connection of the
elements.
It will easily be understood that the element shown in FIG. 10 is a
combination of the embodiment for separating the spinning materials
shown in FIG. 19 and the embodiment for joining the spinning
materials shown in FIG. 24, and that the element shown in FIG. 11
is a combination of the embodiment for separating the spinning
materials shown in FIG. 21 and the embodiment for joining the
spinning materials shown in FIG. 28. Thus, the elements shown in
FIGS. 10 and 11 are capable of joining the spinning materials an
imperfect manner only. In order to increase the layer-multiplying
efficiency, it is necessary to provide at least two inlets I and
outlets O, respectively.
FIGS. 31 - 34 show embodiments of an element including two inlets
I, outlets O and branches M, respectively. Such elements may be
considered to be a combination of two unit passages (repeating
unit) each consisting of a couple of the inlet and outlet. Various
modifications of the shape of the main passage L and branch M and
the arrangement of the outlet O, inlet I and branch M may be made
as shown in FIGS. 31 - 34.
In order to efficiently spin a uniform mixed filament with the aid
of a large number of orifices, the number of the inlet or the
number of the outlet of one element should, for example, be more
than 4 and particularly be more than 8. For this purpose
independent elements may be arranged in parallel. But, such
parallel arrangement is not desirable in view of the fact that the
arrangement makes the spinning apparatus complex in construction,
that the spinning apparatus cannot be made small in size, and
cannot be maintained in an easy manner. Thus, it is most preferable
to arrange a number of units (unit passage) to form an element. An
element including a number of unit passages to the invention will
now be described with reference to FIGS. 35 - 57.
As above described, the inlet I and the outlet O are alternately
arranged. The element or unit passage is classified into three
groups in accordance with the arrangement of the inlet I and the
outlet O.
The first group includes the inlet I provided on the branch M and
the outlet O provided on the main passage L. The second group
includes the inlet I on the main passage L and the outlet O on the
branch M. The third group is a combination of the first and second
groups. FIG. 35 shows an embodiment of the first group, FIG. 36 an
embodiment of the second group and FIG. 37 an embodiment of the
third group. The third group sometimes produces at its one part an
imperfect portion E as shown in FIG. 37.
The element or unit passage is classified into six types in
accordance with the shape of the main passage L.
The first type is one in which the main passage L is made linear
(straight line or slowly inclined curve). FIGS. 35 - 37 show
embodiments of the first type including the linear type main
passage L (This type is called as a linear type hereinafter).
The second type is one in which the main passage L is made zigzag.
FIGS. 38 - 42 show embodiments of the second type including the
zigzag type main passage L (This type is called as a zigzag type
hereinafter.).
The third type is one in which the main passage L is made into a
ladder in shape. FIGS. 43 - 49 show embodiments of the third type
including the ladder type main passage L (This type is called as a
ladder type hereinafter.).
The fourth type is one in which the main passage L is made into a
lattice in shape. FIGS. 50 - 52 show embodiments of the fourth type
including the lattice type main passage L (This type is called as a
lattice type hereinafter.).
The fifth type is one in which the main passage L is made into a
closed loop. FIGS. 57 and 70-77 show embodiments of the fifth type
including the closed loop type main passage L (This type is called
as a closed loop type hereinafter.). This closed loop type is
further classified into four types, i.e. linear type, zigzag type,
ladder type and lattice type.
The sixth type is a combination of the above mentioned five
types.
The linear type element is the most basic element. The linear type
element shown in FIGS. 35 - 37 might be considered to be difficult
to connect them in multi-stages and to be less practicable. But,
the linear type element may easily be connected in multi-stages if
the branch M thereof is bent as shown in FIG. 53.
The zigzag type element is extremely useful. It will be seen that
the zigzag type element shown in FIGS. 38 - 42 may easily be
connected in multi-stages. Similar to the zigzag type element, the
ladder type element and the lattice type element may easily be
connected in multi-stages and are extremely useful.
The shape of the main passage of the zigzag type element is not
limited to zigzag, but includes a gently inclined curve such as a
sine curve as shown in FIG. 59 or more complex or irregular curves.
That is, periodically or oscillatory changing curves may be
considered as the zigzag curves.
The ladder type element is particularly easy to manufacture. The
ladder type element shown in FIG. 43 is the most basic element. The
ladder type element shown in FIG. 43 is closely related to the
zigzag type element shown in FIG. 38. One of the problems
encountered with the elements shown in FIGS. 43 and 45 lies in
occurrence of stagnation of the spinning materials therein. That
is, if each passage is completely symmetrical each other, the
spinning materials cause stagnation in the passage located between
points P and Q and hence do not flow therethrough. The symmetry of
the passage means "symmetry of resistance against the flow of the
spinning materials in the passage". If the passage is completely
symmetrical, the spinning materials are joined at the joining point
with a rate of 1/1 and equally separated at the separating
point.
The element according to the invention may be symmetrical or
unsymmetrical. In order to prevent stagnation of the spinning
materials in the ladder type element the passage must be made
unsymmetrical. In order to make the passage unsymmetrical the
diameter or length of the passage may be changed. FIGS. 44 and 47
show embodiments in which the length of the passage is changed. In
the element shown in FIG. 46 there is produced a pressure
difference between points P and Q, so that stagnation of the
spinning materials does not occur.
In the embodiments shown in FIGS. 44 and 45, the outlet O and the
inlet I are called to be alternately arranged. That is, at least
one inlet I and at least one outlet O may alternately be
arranged.
FIG. 47 shows an embodiment in which provision is made of auxiliary
branch m as shown by dotted lines for the purpose of preventing
stagnation of the spinning materials. The auxiliary branch m should
be smaller in diameter or longer in length when compared with the
branch M, otherwise the branch M would not serve as a branch. For
example, the spinning materials flowing through the auxiliary
branch m should be less than one half, preferably less than one
fourth that flowing through the branch M. Another embodiments
including such auxiliary branch m are shown in FIGS. 49 and 55.
As above mentioned, a number of modified embodiments of the element
or unit passage may be obtained by changing the arrangement of the
branch and the connection of the branch with the main passage, by
bending the branch and main passage and by replacing the inlet with
the outlet. For example, the embodiment shown in FIG. 39
corresponds to that shown in FIG. 38 in whch the inlet and outlet
are replaced by the outlet and inlet, respectively. The inlet and
outlet are determined after the elements have been connected in
multi-stages so that such multi-stage connection constitutes an
extremely important problem. The multi-stage connection of the
elements will be described later, but other modifications of the
elements are possible for those skilled in the art for the purpose
of layer-multiplying as possible or of increasing the mixing
efficiency is referred to FIGS. 19 - 30.
The element according to the invention is developed in
substantially flat plate. A plurality of elements may be arranged
in parallel in the same plane to increase the number of the inlet
and outlet. FIGS. 53 shows an embodiment in which two linear type
elements are arranged in parallel. FIG. 54 shows an embodiment in
which three zigzag type elements are arranged in parallel. FIG. 55
shows an embodiment in which two ladder type elements are arranged
in parallel. It is desirable to make the element as regular as
possible for the purpose of rendering the manufacture and
assembling thereof easy and the mixing efficiency uniform. The
linear, zigzag, ladder or lattice type element is intended to make
its terminal portion irregular or imperfect. Such imperfect
terminal portion when it is not essential part of the element is
allowable, but not desirable. In order to obtain the element having
substantially no imperfect portion, the element should be made as a
closed loop type element having no terminal portions. It is
possible to change the linear, zigzag, ladder or lattice type
element into the closed loop type element by closing the main
passage. An embodiment shown in FIG. 57 is formed by closing the
main passages of double ladder type element. An embodiment shown in
FIG. 72 is formed by closing the zigzag type shown in FIG. 38.
Particularly, the element including at least 4, preferably at least
8 inlets I and outlets O arranged along a circle is mot suitable as
a spinneret for spinning a mixed filament through a number of
orifices arranged along the circle. Similarly, the embodiment
including circular main passages as shown in FIG. 57 can easily be
manufactured with the aid of a lathe and hence is extremely useful
in practice. FIG. 56 shows another embodiment in which the main
passages of the lattice type element are closed into circles and
which is also easy to manufacture in a manner similar to the
embodiment shown in FIG. 57.
As described above, the inventors provide layer-multiplying mixer
consisting of reservoirs and passages for connecting these
reservoirs each other. Such reservoir may be formed by enlarging
the linear portions of the main passages of the element shown in
FIG. 43 or the element shown in FIG. 48. The function of the
reservoir is, however, considerably different from that of the main
passage.
For instance, the residence time of the spinning materials in the
reservoir is entirely different from that in the passage (narrow
path). The layer-multiplying mixer may preferably be formed by the
passage only instead of the reservoir in order to decrease
disturbance of spinning materials. The cross-section of the
reservoir is made larger than that of the passage. In general, the
cross-section of the reservoir is made at least five times,
preferably at least 10 times larger than that of the passage. The
reservoir having a cross-section which is less than five times
larger than that of the passage is not regarded as a reservoir, but
constitutes a passage. For example, a cylinder having a diameter of
5 mm is regarded as a reservoir when compared with a cylindrical
passage having a diameter of 1 mm. But, a cylinder having a
diameter of 2 mm is not regarded as a reservoir.
It is a matter of course that the dimension of passages
constituting the element according to the invention are not
required to be uniform. A groove whose width and depth are in the
order of 0.5 - 5 mm, particularly 1 - 3 mm or a circular hole whose
diameter is in the order of 0.5 - 5 mm, particularly 1 - 3 mm may
be used as the passage. The element according to the invention may
locally include the reservoir or locally thick portion, but the
main portion consists of the passages. The reservoir merely
constitutes an auxiliary portion of the element according to the
invention.
Methods of connecting the elements will be explained hereinafter.
The elements according to the invention are connected each other to
form a multi-stage passage network. The elements should be
connected carefully in such a manner that the spinning materials
are joined and separated in different phase in each element.
FIGS. 58, 59 and 60 show how to connect the elements of the
invention already described with reference to FIGS. 19 - 30 in
multi-stages.
Referring to FIG. 58, spinning materials A and B are joined at a
point J.sub.1 and fed into an element on a surface U.sub.2. An
outlet O.sub.2 of the element on the surface U.sub.2 is connected
to an inlet I.sub.3 of an element on a surface U.sub.3. The joining
direction in the first stage at J.sub.1 is different from the
separating direction in the second stage at S.sub.2 by 90.degree..
The separating direction at S.sub.2 and the joining direction at
J.sub.2 are different by 90.degree.. The joining direction at
J.sub.2 and the separating direction at S.sub.3 are also different
by 90.degree.. Thus, the elements of the present invention are
connected is series and in multi-stages, whereby spinning materials
are joined and separated at multi-stages in different phase. It
will be apparent that the elements on the surfaces U.sub.2 and
U.sub.3 are the same as that shown in FIG. 33. FIG. 59 shows one
embodiment in which the elements shown in FIG. 38 are connected in
multi-stages. FIG. 60 shows one embodiment in which the elements
shown in FIG. 43 are connected in multi-stages. Such a multi-stage
connection can be applied to all of the embodiments of the elements
described above.
It is desirable that the element has a regular shape in view of
multi-stage connections of the elements and of the joinings at the
first stage. Particularly, an element, in which the inlet and/or
the outlet are arranged on a straight line or a gentle curve, such
as a circle, on a surface U, is preferable, because such elements
having the same construction can easily be connected by superposing
them in multi-stages. For example, in FIGS. 38 - 48 the inlet I and
the outlet O are positioned on the same line, and in FIGS. 35, 53
and 55 they are positioned on the different straight lines, and in
FIGS. 57, 72 and 76 they are positioned on the same periphery of a
circle. In each element shown in FIG. 54, the inlet I and the
outlet O are positioned on separate straight lines, but when these
passages are arranged in parallel, the main parts are positioned on
the same straight lines as a whole.
However, according to the invention, it is not limitative that the
inlets I or the outlets O are arranged on a straight line or a
curve in the surface U. For example, a zigzag arrangement may be
used. The inlet I and the outlet O must be arranged carefully so as
that elements can easily be superposed and connected, and further
that the spinning materials can be joined and separated in
different phase efficiently.
The surface U, on which the elements are arranged, may be a plane
or a curved surface. A gently curved surface is regarded as
substantially a flat plane. For example, the surfaces of a cylinder
and cone may be used as such surface U. However, in many cases, a
plane is most effective. The inlet and outlet directions of the
spinning materials are substantially perpendicular to the surface
U. FIGS. 58, 59 and 60 show embodiments in which the direction is
rectangular. It will be apparent from the perspective views shown
in FIGS. 19 - 30 that the most suitable angle is a right angle.
This angle need not be 90.degree. and may for example, be
45.degree., if desired. However, the more the inlet and outlet
angles of spinning materials against the surface are shifted from
90.degree., the more the mixing efficiency becomes lowered. The
inlet and outlet directions of spinning materials should not be
inclined from the perpendicular against the surface U by more than
45.degree..
A supplying portion of spinning materials should be connected to a
mixing apparatus so as to obtain the highest mixing efficiency.
Such a connection is very easy. FIGS. 58, 59 and 60 show the
preferable embodiments.
The first stage joining of spinning materials at J.sub.1 can be
effected by any conventional joining methods, for example, methods
used in spinning composite filaments. Side-by-side type and
sheath-core type joining methods are known most widely.
Particularly the side-by-side type joining method is most effective
for the purpose of the present invention. Furthermore, a joining of
3 components as shown in FIG. 9 or a joining of more than 3
components can be used. The connection of a layer-multiplying mixer
to spinning orifices can be effected in various ways. The outlet O
at the last stage element may be directly connected to an orifice,
and further a reservoir may be interposed between the outlet O and
the orifice. It is also possible that a layer-multiplied spinning
material flow and another flow are bonded and the resulting flow is
supplied to the orifice.
The elements according to the present invention can be combined
with each other or with another element, for example, an element
having reservoirs. Furthermore, the spinning apparatus according to
the present invention may incorporate therein filters, mechanical
stirrers such as screws, and gear pumps. When the filters or
mechanical stirrers are arranged in a layer-multiplying mixer or
between a layer-multiplying mixer and a spinneret plate, spinning
materials can be mixed into finely divided state, but the resulting
filament has a non-continuous construction. It is not necessary
that the spinning apparatus of the present invention is enclosed
wholly in a spinning head. It is possible to put only the spinneret
plate having orifices in the spinning head and to install the mixer
in a separate place.
The passage network of the present invention can be easily
constructed by superposing plates having holes and grooves formed
in the upper and/or base surfaces thereof (This plate is called as
a distributing plate.). Another effective method is to superpose
plates having only holes. Furthermore, the above-mentioned two
kinds of plates may also be combined.
As seen from the above and will be apparent from the following
examples the spinning apparatus, particularly the distributing
plate of the present invention constituting passage networks can be
easily constructed, assembled and maintained. Therefore, extrememly
complicated passage networks can be easily constructed. This
advantage is obtained by the feature that the element is arranged
on the surface U and spinning materials are flowed into or out at a
direction substantially perpendicular to the surface U. Moreover,
it will be seen that the branch M constitutes one of the features
of the present invention, and plays an important role of joining
and separating the spinning materials.
According to the spinning apparatus, particularly passage network
of the present invention, uniform mixed filaments can be spun
through a plenty of orifices, for example, more than four orifices,
particularly more than eight orifices, in a high efficiency. The
apparatus is preferably used in a spinneret having a cylindrical
construction which is used most widely in the industrial production
of filaments at prevent. Furthermore, as the mixer is constructed
by passage networks, the stagnation or disturbance of spinning
materials can be reduced and hence uniform filaments are
obtained.
The elements of the layer-multiplying mixer according to the
invention can be easily connected each other in series and in
multi-stages, so that the number n of joining and separating of
spinning materials in different phase can be made sufficiently
large. For example, it is very easy to make n as large as 10 - 20,
yet the apparatus becomes not so large. The thickness per one stage
of the apparatus (the thickness of the distributing plate) can
easily be made less than 20 mm, and distributing plates having a
thickness of 2 - 10 mm are generally used. Therefore, even when n
is 10, the thickness of a mixer can be made less than 100 mm, so
that sufficiently small-sized mixers can be obtained. Calculation
shows that when n is 10 in the mixer shown in FIG. 8, filaments
composed of 2.sup.10 =1,024 layers can be obtained.
The mix-spinning apparatus according to the invention can be used
in substantially the same manner as used in the conventional
conjugate spinning. That is, spinning materials to be mixed are
separately fed into supplying portions at a velocity determined by
the mixing ratio. As spinning materials, conventional fiber-forming
materials, for example, polyamide; polyester; polyether;
polyolefin; polyvinyl series copolymers, such as polyvinyl
chloride, polystyrene, polyacrylonitrile, polyvinyl alcohol, etc.;
polyurea; polyurethane and copolymers or modified polymers thereof
are used, and furthermore, various materials, which cannot be used
alone for fiber but can be used for mix-spinning, for example,
polyalkylene glycol, and their derivatives, polyethyleneimine,
polyisobutylene, etc., can also be used. The apparatus of the
present invention is applied to wet-, dry- and melt-spinning
methods and any other spinning methods.
The spinneret plate to be used in the present invention can be
selected freely according to the purposes. Any desired number,
arrangement and cross-sectional shape of the orifices can be
selected suitably. Conventional spinneret plates can be used as
such, if desired. Various filaments can easily be spun by changing
spinneret plates. It is one of the advantages of the invention that
the mixer can easily be connected to the spinneret plate as
described above.
The invention will be explained more concretely in the following
examples, which are not limitative within the scope of the
invention.
FIG. 61 is a vertical sectional view of the spinneret of the
present invention. Four distributing plates 10, 20, 30 and 40 are
inserted and superposed one upon the other between two reservoirs 1
and 2 supplying two spinning materials and a spinneret plate 100 to
form a mixer, in which the spinning materials are joined and
separated at 5 stages in different phase. Spinning materials in the
reservoirs 1 and 2 are joined at the tip of a partition 4, and flow
out from inlet holes 11 into passages 12 and 13 arranged in the
base surface of the first-stage distributing plate 10. The base
surface of the distributing plate 10 is shown in FIG. 62. Spinning
materials flowed out from the inlet holes 11 into passages 12 and
13 formed in the base surface of the distributing plate 10 are
separated and joined in the passages 12 and 13, and then flowed out
through holes 21. The hole 21 is the second stage inlet holes.
Therefore, the hole 21 serves as both of the outlet hole of the
first stage and the inlet hole of the second stage. The element of
the spinneret shown in FIG. 61 is the same in construction as that
shown in FIG. 59. The construction of the first stage distributing
plate 10 is the same as that of the second stage distributing plate
20, and these plates are slightly shifted by one-fourth the unit
length of the unit passage (repeating unit) for the purpose of
their connections. The above will be understood from the fact that
the element in the surface U.sub.2 is shifted from the element in
the surface U.sub.3 in FIG. 59. The outlet holes of the fourth
stage distributing plate 40 in the spinneret shown in FIG. 61 are
conduits 101 of the spinneret plate 100. The spinning materials are
extruded from orifices 105 through the conduits 101. The numeral
110 represents a holder. The distributing plate may be provided at
its upper surface with the element contrary to the case in which
the distributing plate is provided at its base surface with the
element as explained with reference to the spinneret shown in FIG.
61. Furthermore, the elements may also be arranged in the upper
surface and in the base surface of the distributing plate
respectively. FIG. 63 shows a distributing plate in which the
element is divided into two portions and these element portions are
arranged in the upper surface and in the base surface,
respectively. When a plenty of distributing plates, in which the
passages 13 arranged in the upper surface and in the base surface
of a distributing plate are connected by means of holes 11, are
superposed, an element having a construction substantially the same
as that of the spinneret shown in FIG. 61 can be obtained. FIG. 64
shows the upper surface of the distributing plate shown in FIG. 63,
and FIG. 65 shows the base surface of the plate.
In the mixing apparatus according to the invention, a distributing
plate can be made by a combination of a plurality of plates. FIG.
66 is a vertical sectional view of a distributing plate made by a
combination of three plates 10a, 10b and 10c. The plate 10a having
passages 13 only, plate 10b having holes 11 only and plate 10c
having passages 12 only are connected correctly by means of a pin
10d. FIG. 67 is a cross-sectional view of the distributing plate
shown in FIG. 66 taken on line 1-1', which shows a communication of
the hole 11 with the passage 13. FIG. 68 is a cross-sectional view
of the spinneret shown in FIG. 66 taken on line 2-2'. FIG. 69 is a
cross-sectional view of the spinneret shown in FIG. 66 taken on
line 3-3', which shows a communication of the passage 12 with the
next stage passage 23.
Holes of all of the plates shown in FIGS. 66 - 69 are composed of
circular holes 11, and elongated holes 13 and 12, so that the
plates can be easily manufactured. For example, punching method and
chemically etching method are used. The plate, in which the
passages (main passage and branch) are composed of grooves as shown
in FIGS. 61 - 65, can be manufactured by chemically etching method
or mechanically cutting method.
FIG. 70 is a vertical sectional view of a spinneret having a
cylindrical construction.
Referring to FIG. 70, five distributing plates 10, 20, 30, 40 and
50 are arranged between a supplying portion consisting of two
reservoirs arranged concentrically and circular spinneret plate
100. Spinning materials can be joined and separated at 5 stages in
different phase. The fifth stage distributing plate 50 serves as a
connecting plate rather than a distributing plate, and is arranged
in order to connect the mixer with a spinneret plate 100. The
spinning materials in the two reservoirs 1 and 2 are joined at the
center of ducts 3, and the joined flow reaches passages 12 and 13
through inlet holes 11 at the first stage distributing plate 10.
The passages 12 and 13 are grooves arranged in the base surface of
the distributing plate 10. FIG. 71 is a cross-sectional view of the
spinneret shown in FIG. 70 taken on line 4-4', which shows an
arrangement of the duct 3 and the inlet hole 11. FIG. 72 is a
cross-sectional view of the spinneret shown in FIG. 70 taken on
line 5-5', which shows an arrangement of the passages 12 and 13
arranged in the base surface of the distributing plate 10. The
connecting points of the passages 12 and 13 with the inlet holes of
the next stage distributing plate, that is, the outlet points at
the first stage are shown by dotted line circles 21.
In FIG. 72, outlets and inlets are arranged on a circle. The
spinning materials are separated in a circumferential direction,
and joined in a diametrical direction, these two directions being
different from each other by 90.degree.. It will be apparent that
the element shown in FIG. 72 corresponds to that obtained by
closing the element shown in FIG. 38. FIG. 73 is a cross-sectional
view of the spinneret shown in FIG. 72 taken on line 6-6', which
shows an arrangement of conduits 104 and orifices 105. In the
spinneret shown in FIG. 70 the number of orifices 105 is 16, which
is larger than the number of outlet holes 0 by 8, so that provision
is made of a connecting plate 50 and a reservoir 106. As described
above, the filters may be arranged in the reservoir, or interposed
between distributing plates. However, it is desirable to arrange
the filters before the reservoirs 1 and 2 in order to obtain a
uniform continuous multi-layer filament.
It will be seen that the spinneret plate 100 shown in FIG. 70 is
not of special structure, but is of usual structure, and it can be
replaced by any other spinneret plates, which are different in the
number and arrangement of orifices.
In the spinneret shown in FIG. 70, the passages are constituted by
grooves and holes formed in the base surface of the distributing
plate. The holes may be inclined in the distributing plate. In
order to communicate easily each connecting portion in the passage,
a small reservoir may be formed at the connecting portion. However,
care must be taken so as not to cause the stagnation of spinning
materials in the reservoir as possible as can. It is necessary the
number of stages of joining and separating the spinning materials
in different phase should be at least two. Usually from several to
twenty stages are used. It will be apparent that a mixer having any
numbers of stages can be very easily manufactured by superposing
distributing plates.
In the spinneret shown in FIG. 70, a zigzag type element is used,
and a spinneret using a ladder type element is shown in FIG.
74.
In the spinneret shown in FIG. 74 the number of joining and
separating the spinning materials in different phase is 5. The
spinneret shown in FIG. 74 is similar to that shown in FIG. 70, but
they are different merely in the element, so that the spinneret
will be easily understood. FIG. 75 is a cross-sectional view of the
spinneret shown in FIG. 74 taken on line 7-7', which shows the
arrangement of reservoirs 1 and 2 and ducts 3. FIG. 76 is a
cross-sectional view of the spinneret shown in FIG. 74 taken on
line 8-8', which shows one embodiment of the ladder type element
formed in the base surface of a distributing plate 10 and closed in
the shape of a circle. It will be apparent that the element shown
in FIG. 76 corresponds to that shown in FIG. 45. A part of the
grooves constituting the main passage shown in FIG. 76 is circular,
so that it may easily be formed by cutting by means of a lathe.
FIG. 77 is a cross-sectional view of the spinneret shown in FIG.
74, which shows that 16 orifices 105 are formed in a spinneret
plate 10. As described above, the number and arrangement of
orifices can be selected freely. When the number of orifices 105 is
smaller than that of outlet passages 51 of a mixer, the number of
layers in the resulting filament is often larger than the
above-mentioned calculated value. On the contrary, even when the
number of orifices 105 is larger than that of outlet passages 51,
the number of layers is seldom decreased. In a cylindrical
spinneret, orifices are preferably arranged in a circle or
symmetrically with repeat to the center of the spinneret, because
filaments are coagulated uniformly.
In the above-mentioned spinnerets (shown in FIGS. 61 - 77), one
element is developed on one distributing plate. However, it is
apparent that two or more elements are arranged in parallel, or
that two kinds or more elements or unit passages are easily
combined. Furthermore, in the spinnerets shown in FIGS. 70 and 74,
it is easy that another spinning material is supplied from another
passage and bonded with the spinning material flowed out from the
outlet passage 51. For example, in the spinneret shown in FIG. 74,
a passage penetrating the distributing plates at the center may be
formed between the reservoir 2 and the reservoir 106, whereby a
part of the spinning material in the reservoir 2 is directly
supplied into the reservoir 106 and bonded with the spinning
material flowed out from the outlet passage 51 of the mixer and
then extruded through the orifice 105.
Suitable gaskets may be interposed between the distributing plates
as usual in order to prevent leakage of the spinning material. A
part of a distributing plate may be made of soft materials, such as
aluminium and lead, whereby the plate can be additionally used as a
gasket. The plate 10a or 10b of the distributing plate shown in
FIG. 66 may be made of soft materials which serve as a gasket.
An orifice having a non-circular shape of opening may be used to
obtain a filament having non-circular cross-section.
* * * * *